Vacuum cleaner incorporating noise suppression system

ABSTRACT

A vacuum cleaner includes a body that carries a suction generator. A final filter is carried on the body downstream from the suction generator. The final filter is oriented along a first plane. Opposed side discharge outlets are carried on the body and oriented along a second plane substantially perpendicular to the first plane. Air is exhausted from the vacuum cleaner through succeeding compartments of increasing volume and rerouted or turned through different planes along a tortuous air path in order to muffle noise produced by the operating vacuum cleaner.

TECHNICAL FIELD

The present invention relates generally to the floor care appliance field and, more particularly, to a vacuum cleaner incorporating a noise suppression system.

BACKGROUND OF THE INVENTION

A vacuum cleaner is an electro-mechanical appliance utilized to effect the dry removal of dust, dirt and other small debris from carpets, rugs, fabrics or other surfaces in both domestic and industrial environments. The vacuum cleaner includes a suction generator generally comprising a fan and drive motor assembly. The suction generator draws an air stream entrained with dirt and debris into the nozzle of the vacuum cleaner. The particulate laden air is then drawn through a dirt collection vessel in the form of, for example, a filter or vacuum cleaner bag, a removable dirt cup or a cyclonic separation chamber and filter combination. The dirt collection vessel traps the dirt and debris from the air stream while substantially clean air is exhausted from the vacuum cleaner.

In order to provide the desired cleaning efficiency, the suction generator must generate a substantial air stream. Space requirements limit the size of the fan of the suction generator and, accordingly, the fan must be driven at relatively high speeds to produce the necessary negative air pressure to provide the desired cleaning action. The noise generated by the motor and the rapidly moving air is substantial in state-of-the-art vacuum cleaners. The present invention relates to a vacuum cleaner incorporating a noise suppression system that substantially reduces the decibel level of an operating vacuum cleaner.

SUMMARY OF THE INVENTION

A vacuum cleaner is provided comprising a nozzle assembly and a canister assembly pivotally connected to the nozzle assembly. The canister assembly includes a primary housing, a bag compartment cover, a motor compartment cover and a filter compartment cover. A bag compartment is formed between the primary housing and the bag compartment cover. A motor compartment is formed between the primary housing and the motor compartment cover. A filter compartment is formed between the bag compartment cover, the motor compartment cover and the filter cover. A filter receiver is provided in the filter compartment. A filter is held in the filter receiver. The filter divides the filter compartment into a first exhaust chamber and a second exhaust chamber. Opposed side discharge outlets are provided in fluid communication with the second exhaust chamber. Still further, a suction generator is held in the motor compartment. The suction generator generates an air stream. The air stream is exhausted from the suction generator and then travels serially through the motor compartment, a vent in the motor compartment cover to the first exhaust chamber, then through the filter to the second exhaust chamber and finally through the opposed side discharge outlets to exit the vacuum cleaner.

The air stream is turned through substantially 90° in the motor compartment. The air stream is again turned through substantially 90° in the first exhaust chamber between the vent and the filter. Further, the air stream is turned through substantially 90° still yet again in the second exhaust chamber between the filter and the opposed side discharge outlets. The turning of the air stream in the first and second exhaust chambers takes place in two separate planes that are substantially perpendicular to one another. Further, the opposed side discharge outlets are positioned outside the two opposing sides of the filter and are formed along a seam between the bag compartment cover and the filter compartment filter.

In accordance with yet another aspect of the present invention a vacuum cleaner is provided comprising a body, a suction generator carried on the body and a final filter carried on the body downstream from the suction generator. The final filter is located along a first plane and opposed side air stream discharge outlets are carried on the body and oriented along a second plane substantially perpendicular to the first plane.

In the following description there is shown and described several different embodiments of the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspect. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the current vacuum cleaner and together with the description serve to explain certain principles of the current vacuum cleaner. In the drawings:

FIG. 1 is a front perspective view of the current vacuum cleaner;

FIG. 2 is a rear perspective view of the vacuum cleaner illustrated in FIG. 1;

FIG. 3 is a schematical diagram illustrating air flow through the vacuum cleaner;

FIG. 4 is a cross sectional view also illustrating air flow through the various compartments or chambers of the vacuum cleaner; and

FIG. 5 is an exploded detailed, perspective view illustrating air flow from the motor cover through the final filter and opposed side discharge outlets;

Reference will now be made in detail to the present preferred embodiment of the vacuum cleaner illustrated in the accompanying drawing figures.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Reference is now made to FIGS. 1, 2 and 3 illustrating an upright vacuum cleaner 10. The vacuum cleaner 10 includes a body in the form of a nozzle assembly 12 and a canister assembly 14. The canister assembly 14 is pivotally connected to the nozzle assembly 12 in the manner of upright vacuum cleaners known in the art. Thus, the canister assembly 14 may be pivoted from the upright storage position illustrated in FIGS. 1 and 2 into an inclined position whereby an operator may freely move the vacuum cleaner 10 to and fro to clean an underlying floor or carpet.

The nozzle assembly includes an agitator cavity 16 that receives a rotary agitator 18. The rotary agitator 18 includes bristle tufts or other resilient projections 20. As the agitator 18 is rotated, the bristle tufts 20 beat dirt and debris from the nap of an underlying carpet or rug being cleaned.

The canister assembly 14 includes a primary housing 22, a bag compartment cover 24, a motor compartment cover 26 and a filter compartment cover 28. As further illustrated in FIGS. 3-5, a bag compartment 30 is formed between the primary housing 22 and the bag compartment cover 24. A motor compartment 32 is formed between the primary housing 22 and the motor compartment cover 26. Further, a filter compartment 34 is formed between the bag compartment cover 24, the motor compartment cover 26 and the filter compartment cover 28. A filter receiver 36 is provided in the filter compartment 34. A filter 38, such as a HEPA filter, is held in the filter receiver 36. The filter 38 divides the filter compartment 34 into a first exhaust chamber 40 and a second exhaust chamber 42. Opposed side discharge outlets 44, 46 are provided in fluid communication with the second exhaust chamber 42. The opposed side discharge outlets 44, 46 are formed along a seam between the bag compartment cover 24 and the filter compartment cover 28. In the illustrated embodiment the opposed side discharge outlets 44, 46 are formed by cooperating recesses or openings 48 molded into the filter compartment cover 28.

A suction generator 50 is held in the motor compartment 32 of the vacuum cleaner 10. The suction generator 50 comprises a fan 52 driven by a cooperating drive motor 54 all held within a suction generator housing 56.

During vacuum cleaner operation, the suction generator 50 draws an air stream through the agitator cavity 16 into the vacuum cleaner 10. Dirt and debris loosened by the rotary agitator 18 are entrained in this air stream and directed through an inlet 58 into the vacuum cleaner or filter bag 60 held in the bag compartment 30. Dirt and debris are collected and retained in the vacuum cleaner bag 60 while relatively clean air is drawn through the side wall of the bag into the inlet 62 of the suction generator 50.

The air stream is directed over the drive motor 54 of the suction generator 50 so as to provide cooling before being exhausted through radially oriented openings 64 in the suction generator housing 56 into the motor compartment 32. Next, the air stream passes through the vent 66 in the motor compartment cover 26 into the first exhaust chamber 40.

From there the air stream passes through the final filter 38 into the second exhaust chamber 42. Then the air stream passes through the opposed side discharge outlets 44, 46 exiting the vacuum cleaner.

As should be appreciated, between the suction generator inlet 62 and the opposed side discharge outlets 44, 46, the air stream passes through a series of chambers 32, 40, 42 and is rerouted or turned and subjected to expansion within those chambers in order to muffle the noise generated by the vacuum cleaner 10. The tortuous air path includes (a) a substantially 90° turn in the motor compartment 32 between the suction generator inlet 62 and the vent 66; (b) a second substantially 90° turn in the first exhaust chamber 40 between the vent 66 and the filter 38; and (c) a third substantially 90° turn in the second exhaust chamber 42 between the filter 38 and either of the opposed side discharge outlets 44, 46. As a result, the air stream travels through the vent 66 in a first direction, the filter 38 in a second direction substantially perpendicular to the first direction and the opposed side discharge outlets 44, 46 in third and fourth directions both substantially perpendicular to the first and second directions.

The motor compartment 32 has a volume V₁, the first exhaust chamber 40 has a volume V₂, and the second exhaust chamber 42 has a volume V₃ where V₁<V₂<V₃. Thus, it should be appreciated that the air stream also passes serially through three different compartments 32, 40, 42 each having an increase in volume. With each successive chamber expansion, the speed of the air stream slows and, accordingly, the noise generated by the air stream once it is eventually exhausted through the opposed side discharge outlets 44, 46 is reduced. Here it should also be noted that the motor compartment 32 also has a greater volume than the suction generator housing 56 and thereby represents yet another expansion phase. The air stream also undergoes an additional 90° turn traveling through the suction generator housing 56 (i.e. enters through the inlet 62 traveling along a path parallel to the axis of the suction generator drive shaft and exits radially through the openings 64).

As illustrated, it should also be appreciated that the filter compartment cover 28 overlies the face of the filter 38 forming a solid, continuous wall which forces the air stream to turn toward the opposed side discharge outlets 44, 46 that are positioned outside the two opposing sides 68, 70 of the filter 38. The deflected, rather than direct inline, exhaust from the filter further muffles noise generation.

It should also be appreciated that the vent 66 forms a first opening having a surface area A₁ while the opposed side discharge outlets 44, 46 form a second combined opening having a surface area A₂ where A₁<A₂. This increase in the cross sectional surface area of the vent 66 and the combined discharge outlets 44, 46 further reduces the back pressure of the system, decreases air stream speed and reduces noise generation.

The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings For example, while the illustrated vacuum cleaner 10 is equipped with a vacuum cleaner bag 60, it should be appreciated that it may be equipped instead with a dirt cup or other cleaning vessel. Further, while an upright vacuum cleaner is disclosed, it should be appreciated that a canister vacuum cleaner could be provided.

The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way. 

What is claimed:
 1. A vacuum cleaner, comprising: a nozzle assembly; and a canister assembly pivotally connected to said nozzle assembly; said canister assembly including a primary housing, a bag compartment cover, a motor compartment cover and a filter compartment cover; a bag compartment formed between said primary housing and said bag compartment cover; a motor compartment formed between said primary housing and said motor compartment cover; a filter compartment formed between said bag compartment cover, said motor compartment cover and said filter cover; a filter receiver in said filter compartment; a filter held in said filter receiver, said filter dividing said filter compartment into a first exhaust chamber and a second exhaust chamber; opposed side discharge outlets in fluid communication with said second exhaust chamber; and a suction generator held in said motor compartment and generating an air stream, said air stream being exhausted from said suction generator and traveling serially through said motor compartment, through a vent in said motor compartment cover to said first exhaust chamber, through said filter to said second exhaust chamber and then through said opposed side discharge outlets to exit said vacuum cleaner.
 2. The vacuum cleaner of claim 1, wherein said suction generator inlet and said vent are oriented to turn said air stream through substantially 90° in said motor compartment.
 3. The vacuum cleaner of claim 1, wherein said vent and said filter are oriented to turn said air stream through substantially 90° in said first exhaust chamber.
 4. The vacuum cleaner of claim 1, wherein said filter and said opposed side discharge outlets are oriented to turn said air stream through substantially 90° in said second exhaust chamber.
 5. The vacuum cleaner of claim 1, wherein said air stream is turned through substantially 90° in each of said motor compartment, said first exhaust chamber and said second exhaust chamber.
 6. The vacuum cleaner of claim 5, wherein said motor compartment has a volume V₁, said first exhaust chamber has a volume V₂ and said second exhaust chamber has a volume V₃ where V₁<V₂<V₃.
 7. The vacuum cleaner of claim 2, wherein said side discharge outlets are formed along a seam between said bag compartment cover and said filter compartment cover.
 8. The vacuum cleaner of claim 1, wherein said air stream is turned in said first exhaust chamber along a first plane and said air stream is turned in said second exhaust chamber along a second plane where said first and second planes are perpendicular to one another.
 9. The vacuum cleaner of claim 1, wherein said opposed side discharge outlets are positioned outside two opposing sides of said filter.
 10. The vacuum cleaner of claim 1, wherein said air stream flows in a first direction through said vent, in a second direction through said filter and then through opposing third and fourth directions through said opposed side discharge outlets.
 11. The vacuum cleaner of claim 1, wherein said motor compartment has a volume V₁, said first exhaust chamber has a volume V₂ and said second exhaust chamber has a volume V₃ where V₁<V₂<V₃.
 12. The vacuum cleaner of claim 11, wherein said vent forms a first opening having a surface area A₁ and said opposed side discharge outlets form a second combined opening having a surface area A₂ where A₁<A₂.
 13. A vacuum cleaner, comprising: a body; a suction generator carried on said body; a final filter carried on said body downstream from said suction generator and oriented along a first plane; and opposed side air stream discharge outlets carried on said body and oriented along a second plane substantially perpendicular to said first plane.
 14. The vacuum cleaner of claim 13, wherein said body includes a motor compartment, holding said suction generator, a first exhaust chamber and a second exhaust chamber serially connected for passage of an air stream generated by said suction generator.
 15. The vacuum cleaner of claim 14, wherein said motor compartment has a volume V₁, said first exhaust chamber has a volume V₂ and said third exhaust chamber has a volume V₃ where V₁<V₂<V₃.
 16. The vacuum cleaner of claim 15, wherein said suction generator inlet and said vent are oriented to turn said air stream substantially 90° in said motor chamber, said vent and said filter are oriented to turn said air stream substantially 90° in said first exhaust chamber and said filter and said opposed side discharge outlets are oriented to turn said air stream substantially 90° in said second exhaust chamber.
 17. The vacuum cleaner of claim 13, further including a dirt collection vessel carried on said body upstream from said suction generator.
 18. The vacuum cleaner of claim 17, wherein said dirt collection vessel is a vacuum cleaner bag.
 19. The vacuum cleaner of claim 13, wherein said vacuum cleaner is an upright vacuum cleaner. 